Removing retaining rings
Pic. 3.105. removal of retaining rings
Before removing the retaining ring, mark the relative position of the crosses and universal joint forks (pic. 3.105).
Remove the circlips with the special tool.
Removing the universal joint bearing
Pic. 3.106. Removing the universal joint bearing
Using a special tool, press the bearing out of the cross and universal joint yoke (pic. 3.106).
Attention! It is not allowed to knock out the bearings when removing, as this can lead to imbalance of the cardan shaft.
Removing mounting bolts
CV joint with length compensator (DOJ) complete
Pic. 3.107. Marks of the relative position of the flange and CV joint with length compensator (DOJ) complete
Mark the relative position of the flange and CV joint with length compensator (DOJ) complete (pic. 3.107).
Turn away bolts of fastening of the SHRUS with the compensator of length (DOJ) assembly and disconnect the CV joint from the flange.
Removing the self-locking nut/removing the flange
Pic. 3.108. Labels for the relative position of the rear driveshaft and flange
Mark the relative position of the rear driveshaft and flange (pic. 3.108).
Remove the flange from the rear driveshaft.
Removing the intermediate support assembly
Remove the intermediate support assembly.
Pic. 3.109. Removing the intermediate support assembly
Pull out the intermediate support bracket and install the special tool (pic. 3.109).
Removing the CV joint with length compensator (DOJ)
Pic. 3.110. Removing the protective cover
Remove the protective cover from the CV joint «Lebro» complete (pic. 3.110).
Pic. 3.111. Ball and cage position
Apply alignment marks for the relative position of the outer race, separator and inner races of the CV joint using a scriber (pic. 3.111).
Note. Write down the location of the balls so as not to confuse their original location when installing.
Pic. 3.112. Removal of the inner cage and the CV joint separator from the front propeller shaft
With the help of the universal (mass-produced) puller, remove the inner race and the CV joint separator from the front propeller shaft (pic. 3.112).
Removing the protective cover of the CV joint with length compensator (DOJ)
Pic. 3.113. Removing the protective cover of the CV joint
If it is planned to re-install the protective cover of the CV joint with a length compensator (DOJ), then before removing the protective cover of the CV joint, wrap the splines of the rear propeller shaft with insulating tape (pic. 3.113).
Examination
Check propeller shaft splines for wear or damage.
Pic. 3.114. SHRUS separator «Lebro»
Check the ball grooves on the outer race and the inner race of the CV joint «Lebro» for uneven wear, damage or rust (pic. 3.114).
Check the surface of the balls for rust, wear or other damage.
Check the CV joint separator «Lebro» for rust or damage.
Installation of a protective cover SHRUS with a length compensator (DOJ)
Pic. 3.115. Protective cover installation
Wrap the splines of the cardan shaft with insulating tape and install the protective cover of the CV joint with length compensator (DOJ) (pic. 3.115).
Installation of CV joint with length compensator (DOJ)
Apply a light coat of special grease to the ball grooves on the outer and inner races of the CV joint.
Recommended grease: REAMAX FS No.1
Pic. 3.116. Lubrication points
Install the separator on the inner race of the CV joint, aligning the alignment marks, and install the two balls so that they are located in mutually opposite grooves. In this case, both balls should be installed in the same grooves in which they were installed before disassembling the CV joint (pic. 3.116).
Pic. 3.117. Installing the inner race and separator
Install the inner race and separator assembly into the outer race, aligning the alignment marks of their relative position (pic. 3.117).
Install the rest of the balls in the grooves according to their original location.
Check that the CV joint outer race rotates smoothly on the outer race.
Apply special grease to the CV joint with length compensator (DOJ) assembled.
Recommended lubricant: REAMAX FS NO. 1 (95±5 grams).
Pic. 3.118. Places for applying glue
Apply a small amount of special adhesive at three points on the surface of the ball grooves, spaced at the same distance from each other around the circumference of the CV joint with length compensator (DOJ), in which there are grooves for the rubber seal and then install the rubber seal on the CV joint with length compensator (DOJ) (pic. 3.118).
Recommended Adhesive: 3M ATD Part No. Quick Dry Adhesive 8121, 3M ATD Part No. 8155 or equivalent
Pic. 3.119. Installing a CV joint using a tool head
Install CV joint with length compensator (DOJ) assembled on the cardan shaft, aligning the holes for the mounting bolts. Install a suitable tool head on the inner race of the CV joint and, by tapping with a hammer with a plastic head, ensure a tight fit of the CV joint into place (pic. 3.119).
Note. When installing, position the CV joint with length compensator (DOJ) so that the side with the grooves, on which the CV joint rubber seal was previously installed, is directed to the protective cover of the CV joint.
Re-align the bolt holes on the CV joint boot and the CV joint with the length compensator (DOJ) assembly using the mounting bolts, and install the protective cover on the CV joint.
Install the flange rubber seal on the flange. The installation procedure is completely similar to the procedure described above.
Installing the protective boot clamp
Pic. 3.120. Position of the lock of a collar of a protective cover
Attention! Position the protective boot tie lock so that it is on the opposite side of the protective boot from the boot's ventilation bosses. Make sure there is no grease around the boot lugs as grease will obstruct ventilation through the channels (pic. 3.120).
Installation of intermediate support assembly / installation of flange / installation of self-locking nut
Install the bearing and retainer into the groove of the intermediate bearing.
Pic. 3.121. Scheme of installation of an intermediate support
Install the intermediate support assembly on the front propeller shaft so that the intermediate support boot is located on the side of the front propeller shaft (pic. 3.121).
Pic. 3.122. Alignment of marks on the flange and rear driveshaft
Align the previously made alignment marks on the relative position on the flange and the rear driveshaft (pic. 3.122).
Press the flange and intermediate support assembly firmly while tightening the self-locking nut.
Installing the CV joint mounting bolts with a length compensator (DOJ) complete
Align the previously made relative position marks on the flange and CV joint with the length compensator (DOJ) assembled before installing the mounting bolts.
Connect the flange and CV joint with the length compensator (DOJ) assembled with mounting bolts.
Check flange and CV joint with length compensator (DOJ) for lubricant leaks.
Installation of intermediate support assembly
Pic. 3.123. Scheme of installation of an intermediate support
Install the bearing and retainer into the groove of the rubber support of the intermediate support mounting bracket (pic. 3.123).
Install the intermediate support boot assembly so that it is located on the front side.
Installing the universal joint cross and bearings of the universal joint
Pic. 3.124. Grease Application Points
Apply multipurpose grease to the following parts of the gimbal and bearings (pic. 3.124).
Necks and oil collecting grooves of the cross.
Working edges of seals.
Needle bearings.
Recommended lubricant: ALVANIA EP GRADE No.2
Attention! Do not over-lubricate. Excess lubrication will result in assembly difficulties and improper selection of circlips.
Using the special tool, press the bearings into the universal joint yokes in accordance with the following sequence of operations.
Install the appropriate mandrel on the special tool.
Install both bearings in the universal joint yoke and press them in using the special tool.
Installing retaining rings
Pic. 3.125. Retaining Ring Installation Diagram
Install circlips of the same thickness on both sides of the universal joint yoke.
Using a brass drift, press the bearing and cross into the universal joint yoke on one side.
Measure the axial clearance of the universal joint bearing (between circlip and bearing) with a flat feeler gauge. If the axial clearance exceeds the maximum allowable value, then adjust it by selecting a retaining ring of suitable thickness.
Nominal value: 0.02 - 0.06 mm.